TOYOTA AVENSIS 2005 Service Repair Manual

A77404
B
A
BBBB
A
B
A77304
A77305
A77405
A
B
A
A
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
14±215
AVENSIS REPAIR MANUAL (RM1018E)
(b)Install the front suspension member braces with the 8
bolts.
Torque:
Bolt A 133 N
m (1,356 kgf
cm, 98 ft
lbf)
Bolt B 80 N
m (816 kgf
cm, 59 ft
lbf)
132.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 87 N
m (887 kgf
cm, 64 ft
lbf)
133.INSTALL TRANSVERSE ENGINE ENGINE MOUNTING INSULATOR
Torque: 52 N
m (530 kgf
cm, 38 ft
lbf)
134.INSTALL ENGINE MOUNTING BRACKET NO.2 RH Torque:
A 52 N
m (530 kgf
cm, 38 ft
lbf)
B 113 N
m (1,152 kgf
cm, 83 ft
lbf)
135.REMOVE ENGINE HANGERS
136.INSTALL STEERING INTERMEDIATE SHAFT ASSY NO.2 (See page 50±9)
137.INSTALL TRANSMISSION CONTROL CABLE ASSY (M/T TRANSAXLE) (See page 41±24)
138.INSTALL TRANSMISSION CONTROL CABLE ASSY (A/T TRANSAXLE) (See page 40±25)

A77298
LHD Steering Position typeRHD Steering Position type
AB
A
A
AA
A
C
C
C
C
C
C
B
14±216
±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
139.INSTALL CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE)
Torque:
Bolt A 12 N
m (122 kgf
cm, 89 ft
lbf)
Bolt B 9.0 N
m (92 kgf
cm,79 in.
lbf)
Bolt C 5.0 N
m (51 kgf
cm,44 in.
lbf)
140.INSTALL FRONT AXLE ASSY LH
Torque: 294 N
m (3,000 kgf
cm,217 ft
lbf)
141.INSTALL FRONT AXLE ASSY RH Torque: 294 N
m (3,000 kgf
cm,217 ft
lbf)
142.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (M/T TRANSAXLE)
Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
143.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 LH (A/T TRANSAXLE) Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
144.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (M/T TRANSAXLE) Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
145.INSTALL FRONT SUSPENSION ARM SUB±ASSY LOWER NO.1 RH (A/T TRANSAXLE) Torque: 142 N
m (1,448 kgf
cm,104 ft
lbf)
146.INSTALL FRONT STABILIZER LINK ASSY LH Torque: 74 N
m (755 kgf
cm,55 ft
lbf)
147.INSTALL FRONT STABILIZER LINK ASSY RH Torque: 74 N
m (755 kgf
cm,55 ft
lbf)
148.INSTALL TIE ROD END SUB±ASSY LH (See page 51±36)
149. INSTALL TIE ROD END SUB±ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
150.INSTALL FRONT AXLE HUB LH NUT (See page 30±6)
151. INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
152.INSTALL EXHAUST PIPE ASSY FRONT (See page 15±7)
153.INSTALL EXHAUST PIPE ASSY CENTER (See page 15±7)
154. INSTALL FLOOR PANEL BRACE FRONT Torque: 30 N
m (306 kgf
cm, 22 ft
lbf)
155. INSTALL COOLER BRACKET (LHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
156. INSTALL ENGINE SERVICE COVER BRACKET RH (RHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)
157. INSTALL COOLER REFRIGERANT SUCTION HOSE NO.1 (LHD STEERING POSITION TYPE) Torque: 9.0 N
m (92 kgf
cm, 80 in.
lbf)

±
ENGINE MECHANICAL PARTIAL ENGINE ASSY(1AZ±FSE)
14±217
AVENSIS REPAIR MANUAL (RM1018E)
158.INSTALL OIL RESERVOIR BRACKET NO.1
Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
159.INSTALL RETURN TUBE SUB±ASSY
Torque: 8.0 N
m (82 kgf
cm,71 in.
lbf)
160.INSTALL RADIATOR RESERVE TANK SUB±ASSY Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
161.INSTALL BATTERY CARRIER
162.INSTALL AIR CLEANER ASSEMBLY WITH HOSE
Torque: 5.0 N
m (51 kgf
cm,44 in.
lbf)
163.INSTALL COMPRESSOR AND MAGNETIC CLUTCH Torque: 25 N
m (255 kgf
cm,18 in.
lbf)
164.INSTALL GENERATOR ASSY (See page 19±20)
165.INSTALL FAN AND GENERATOR V BELT (See page 14±185)
166.INSTALL RADIATOR ASSY (See page 16±36)
167. INSTALL RADIATOR RELAY BLOCK Torque: 5.0 N
m (51 kgf
cm, 44 in.
lbf)
168. INSTALL ENGINE COVER SUB±ASSY NO.1 Torque: 7.0 N
m (71 kgf
cm, 62 in.
lbf)
169. ADD MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
170. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
171. ADD ENGINE OIL
172.ADD COOLANT (See page 16±31)
173.ADD POWER STEERING FLUID (See page 51±4)
174. BLEED POWER STEERING FLUID
175. CHECK FOR ENGINE OIL LEAKS
176.CHECK FOR ENGINE COOLANT LEAKS (See page 16±25)
177.CHECK FOR FUEL LEAKS (See page 11±30)
178. INSTALL FRONT WHEELS Torque: 103 N
m (1,050 kgf
cm, 76 ft
lbf)
179.ADJUST FRONT WHEEL ALIGNMENT (See page 26±6)
180.INSPECT CHECK IDLE SPEED AND IGNITION TIMING (See page 14±204)
181. INSPECT CO/HC
182. CHECK ABS SPEED SENSOR SIGNAL

141BE±01
A77310
Engine Room
Cover Side
Radiator Support
Opening CoverEngine Cover Sub±assy No. 1
Fan and Generator V Belt
Engine Under Cover LH
7.0 (71, 62 in.
lbf)
7.0 (71, 62 in.
lbf)
Engine Under Cover RH
N´m (kgf´cm, ft´lbf)
: Specified torque 14±192
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)
PARTIAL ENGINE ASSY (1AZ±FSE)
COMPONENTS

A77521
Generator Assy Cooler Refrigerant
Suction Hose No. 1
(RHD Steering Position Type)
Radiator Hose Inlet
Radiator Hose OutletCooler Refrigerant Suction Hose No. 1
(LHD Steering Position Type)
Union to Connector
Tube Hose
Charcoal Canister Assy
Battery TrayBatteryRadiator Assy
Compressor and
Magnetic Clutch
Battery Clamp
Battery CarrierAir Cleaner Assembly with Hose
Radiator Relay Block
52 (530, 38)
9.8 (100, 7.2)
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)
13 (133, 10)
25 (250, 18)
5.0 (51, 44 in.
lbf)
21 (214, 16)
7.0 (71, 62 in.
lbf)
7.0 (71, 62 in.
lbf)
19 (194, 14)
19 (194, 14)
N´m (kgf´cm, ft´lbf)
: Specified torque
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
14±193
AVENSIS REPAIR MANUAL (RM1018E)

A80059
30 (306, 22)
Radiator Reserve
Tank Sub±assy
Fuel Tube Sub±assy
Exhaust Pipe Assy center

Gasket

Gasket
Gasket
Floor Panel Brace Front Vane Pump Oil
Reservoir Assy
Accelerator Control
Cable Sub±assy
Fuel Pipe Clamp
Exhaust Pipe Assy Front
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
8.0 (82, 44 in.
lbf)
Return Tube
Sub±assy
43 (440, 32)
5.0 (51, 44 in.
lbf)
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
43 (440, 32)
43 (440, 32)
43 (440, 32)
43 (440, 32)
43 (440, 32)
5.0 (51, 44 in.
lbf)
14±194
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)

A77313
Cooler Bracket
(LHD Steering Position Type)
Oil Reservoir
Bracket No. 1Heater Outlet Water Hose
Heater Inlet Water Hose
Steering Intermediate
Shaft Assy No. 2
Column Hole Cover Silercer Sheet
Front Stabilizer Link Assy
Front Axle Assy
35 (360, 26)
7.0 (71, 62 in.
lbf)
74 (755, 55)
216 (2,203,159 )
142 (1,448,105 )
N´m (kgf´cm, ft´lbf)
: Specified torque

Non±reusable part
Front Axle Hub Nut
Tie Rod End Sub±assy
5.0 (51, 44 in.
lbf)
5.0 (51, 44 in.
lbf)

Cotter Pin
49 (500, 36)
Front Suspension Arm
Sub±assy Lower No. 1
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
14±195
AVENSIS REPAIR MANUAL (RM1018E)

A77314
A/T:
Clip
Transmission
Control Cable Assy
N´m (kgf´cm, ft´lbf)
: Specified torque
M/T:
Transmission Control
Cable Assy
5.0 (51, 44 in.
lbf)
12 (120, 9.0)
M/T:
Clutch Release
Cylinder Assy
12 (122, 8.9)
Clip
5.0 (51, 44 in.
lbf)
9.0 (92, 80 in.
lbf)
14±196
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)

A77315
87 (887, 64)
37 (377, 27)
52 (530, 38)
87 (887, 64)52 (530, 38)
52 (530, 38)
52 (530, 38)52 (530, 38)
52 (530, 38)
133 (1,356, 83)
80 (816, 59)
80 (816, 59)
133 (1,356, 83)
45 (459, 33)
133 (1,356, 83)
Engine Mounting Bracket No. 2 RH
Transverse Engine
Engine Mounting Insulator
Front Suspension Brace RH
Front Suspension
Brace LH
Front Drive Shaft Assy RH
Front Drive Shaft Assy LH Engine Assembly
with Transaxle
Front Suspension Crossmember
w/ Center Member
N´m (kgf´cm, ft´lbf)
: Specified torque
Vane Pump Assy
113 (1,152, 83)
87 (887, 64)
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
14±197
AVENSIS REPAIR MANUAL (RM1018E)

A77371
Engine Assy
Drive Shaft Bearing Bracket
Wire Clamp Bracket
Manual Transaxle Assy
Starter AssyClutch Disc Assy Flywheel Sub±Assy
8

7
Clutch Cover Assy
N´m (kgf´cm, ft´lbf)
: Specified torque M/T:
34 (347, 25)
46 (470, 34)
13 (130, 9)
39 (398, 29)
64 (650, 47)
19 (194, 14)
44 (440, 32)
46 (470, 34)
130 (1327, 96)
14±198
± ENGINE MECHANICALPARTIAL ENGINE ASSY (1AZ±FSE)
AVENSIS REPAIR MANUAL (RM1018E)